Integrated heat exchanger support and sealing structure

ABSTRACT

An apparatus is disclosed for supporting and sealing a heat exchanger unit. Specifically, a heat exchanger is disclosed comprising a pair of integrated header units arranged in parallel relation to each other. Each header unit comprises a radiator header and a condenser. The radiator unit and condenser maintain separate heat exchange fluid flowpaths. A plurality of parallel heat transfer tubes is connected perpendicularly to said integrated headers, and a plurality of fins extend between adjacent heat transfer tubes of the radiator. A fin unit including a plurality of fins is mounted to an outside surface of an outermost heat transfer tube, and an integrated side support is connected to the fin unit and integrated headers.

FIELD OF THE INVENTION

[0001] The present invention relates to heat exchangers. In particular,the invention relates to a structural improvement for sealing andsupporting heat exchanger elements.

BACKGROUND OF THE INVENTION

[0002] Heat exchangers are utilized in conventional automobiles todissipate heat from the engine, or to provide heat exchange to theinterior of the car such as with air-conditioning. Typically, theseautomotive components take the form of radiator structures that arepositioned in front of a cooling fan and behind the intake grill. Otherheat exchanger structures can include condensers and evaporators.

[0003] As currently produced, heat exchangers are constructed from avariety of components. For example, radiator header units are composedof headers, tanks, inlet and outlet pipes. The radiator headers aretypically connected in perpendicular relation to a heat exchanger core.The core of a radiator consists of a plurality of heat transfer tubesand fins which serve to dissipate heat from the coolant that is cycledthrough the heat exchanger. The heat transfer tubes and fins aretypically arranged to maximize their exposure to a moving airflow. Thecore of a heat exchanger is most often affixed to side supports that, inturn, are welded or otherwise affixed to end caps which seal or capheaders or tanks. Thus, the manufacture of a heat exchanger is a complexprocess that involves welding, or otherwise affixing, numerous partsinto a cohesive unit.

[0004] With respect to side supports and end caps for heat exchangers,the current practice is to affix end caps to each end of a side supportduring the manufacturing process. Once pieced together, the side supportand end caps are affixed to the heat exchanger core and the heatexchanger headers or tanks. Specifically, the side support is affixed inadjacent fashion to the core of the heat exchanger. The end caps, inturn, are affixed to the header units of the heat exchanger. Thus, thecurrent practice utilizes at least three separate pieces to support theheat exchanger core and seal the heat exchanger headers or tanks—a sidesupport with an end cap component located on each end of the sidesupport.

[0005] In sum, the current manufacture of heat exchangers is a complexand expensive undertaking. As has been described, this is due, in largepart, to the assembly and construction of multiple mechanical componentsthat must be blended into a cohesive sum.

SUMMARY OF THE INVENTION

[0006] The present invention relates to an integrated side supportcapable of supporting, uniting and sealing at least one heat exchanger.By having a one-piece, integrated side support, manufacturing costs aresubstantially reduced. Collateral benefits such as reduced leakage andbetter overall structural integrity are also derived from the presentinvention.

[0007] In one embodiment of the present invention, a heat exchanger isdisclosed comprising a pair of integrated header units arranged inparallel relation to each other. Each header unit comprises a radiatorheader and a condenser. The radiator unit and condenser maintainseparate heat exchange fluid flowpaths. A plurality of parallel heattransfer tubes is connected perpendicularly to said integrated headers,and a plurality of fins extend between adjacent heat transfer tubes ofthe radiator. A fin unit including a plurality of fins is mounted to anoutside surface of an outermost heat transfer tube, and an integratedside support is connected to the fin unit and integrated headers.

[0008] In another embodiment of the invention, an apparatus forsupporting a pair of integrated headers arranged in parallel relation toeach other is disclosed. A side support is mounted adjacent to both ofsaid integrated headers, and an end cap means is integrated with saidside support for sealing said integrated headers. A securing means isprovided extending from said end cap to said header.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] These and other features of the invention will appear from thefollowing written description, and from the drawings, in which:

[0010]FIG. 1 is a perspective of one embodiment of a heat exchangerassembly of the present invention.

[0011]FIG. 2 is a perspective view of a side support removed from theembodiment of FIG. 1 in accordance with the present invention.

[0012]FIG. 3 is a sectional view of the interface between the integratedheader, integrated side support and core of the heat exchanger of FIG.1.

DESCRIPTION OF THE PREFERRED EMBODIMENT

[0013]FIG. 1 shows a perspective view of a heat exchanger unit with thepreferred embodiment incorporated therein. As shown in the drawing, theheat exchanger has two integrated header units 1, 2, each containing aradiator header 1 and a condenser 2 (more fully shown in FIG. 3),arranged in parallel relation to each other. The first preferredembodiment of the invention is an integrally molded side support thatincludes a side support component 3 and end caps 4, each end cap 4 withat least two cap members 4 a, 4 b (more fully shown in FIG. 3) locatedat each end of the side support component. As shown in the drawing, theside support component 3 supports the heat exchanger core 8. The endcaps 4 operate to seal the radiator headers 1 and the condenser 2. Theaddition of expansion joints 6 on each end of the side support componentcan also be seen from this drawing. This drawing also shows theinclusion of reinforcement tabs 5 in the preferred embodiment of thepresent invention.

[0014]FIG. 2 is a perspective view of a first preferred embodiment ofthe present invention viewed removed from the other componentsillustrated in FIG. 1. As shown in the drawings, the preferredembodiment includes a substantially flat portion 3 a for the sidesupport 3 to the heat exchanger core 8. The preferred embodiment furtherincludes end caps 4 on each end of the side support, each with two capmembers 4 a, 4 b.

[0015] Referring specifically to FIG. 3, it can be clearly seen that, ascontemplated by the present invention, the integrated header unitcomprises two adjacent and attached heat exchanger units—the radiatorheader 1 affixed to the condenser 2. Each component of the integratedheader unit functions as a separate and autonomous unit. Althoughaffixed to one another, the two heat exchanger components remainpartitioned so that each can serve its separate function independentlyof the other. FIG. 3 further shows an enlarged view of the interfacebetween the integrated side support end cap 4 and the integrated headerunit 1, 2. It is also shown that the preferred embodiment includesreinforcing tabs 5 arranged in a roughly equidistant fashion around theend caps 4. The preferred embodiment also includes expansion joints 6 oneach end of the side support to allow for the expansion and contractionof the heat exchanger core 8 during heating and cooling cycles. As canbe clearly seen from the drawing, the preferred embodiment of thepresent invention is preferably an integrally molded component thatincorporates all of these features.

[0016] Referring again to FIG. 3, each end cap 4 has two cap members 4a, 4 b. One cap member 4 a coincides in shape with the oblongcross-sectional configuration of the radiator 1 while the second capmember 4 b is shaped substantially round so as to coincide with theround cross-sectional shape of the condenser 2. The two cap members 4 a,4 b are integrally molded so that the end cap is preferably a unitarystructure that incorporates both cap members. Thus, in the preferredembodiment, the integrated side support caps two heat exchanger units 1,2 with a unitarily structured end cap 4 that has two cap members 4 a, 4b.

[0017] In the preferred embodiment, each cap member 4 a, 4 b fits to theouter diameter of a coinciding heat exchanger component. As stated, onecap member 4 a is adapted to fit the radiator header 1 and the other capmember 4 b is adapted to fit the condenser 2. Of note is that withineach cap member, there is an indentation that coincides with the innerdiameter of each coinciding heat exchanger component. The indented partof the cap member fits within the inner diameter of the coinciding heatexchanger component thus being positioned similarly to a plug. The endcap 4 is then affixed to the integrated header units 1,2 through theprocess of brazing.

[0018] The placing of indentations within the cap members 4 a, 4 b so asto fit within the diameter of the heat exchanger header improves thefunction of the heat exchanger. Heat exchangers involve the cycling offluid throughout their various components. Thus, structural integrity isof vital importance so that components do not leak the fluid that isessential to the operation of the heat exchanger. By placing the capmember 4 a, 4 b in the inner diameter of the corresponding heatexchanger header in the way of the preferred embodiment, a cleaner andmore secure fit between the cap member and the header is ensured and theoverall structural integrity of the unit is enhanced. The alignment ofthe cap member 4 a, 4 b with the outer surface of the heat exchanger(s)also streamlines the design of the end cap-to-header interface. It iscontemplated that a variety of shapes could be utilized for a cap memberdepending on the heat exchanger cross-sectional shape for which the capmember is to be united. The requirements for designing other cap memberconfigurations would only require altering the design and stampspecifications of the end cap.

[0019] In addition to the unique configuration of the end cap 4, aplurality of reinforcing tabs 5 are also included in the presentinvention so as to better secure the end caps 4 to the heat exchangercomponents. The reinforcing tabs 5 are positioned along the outersurface of the end cap 4, and specifically, along the outer surface ofeach cap member 4 a, 4 b. The reinforcing tabs 5 extend radially and arebent axially to contact the surface of the attached header unit. Thereinforcing tabs are secured to the header units through the samebrazing process that is used to affix the end caps 4 to the integratedheader units 1,2. In the preferred embodiment, three reinforcing tabs 5are positioned in a roughly equidistant relationship to one anotheralong the outer surface of each cap member 4 a, 4 b. The number ofreinforcing tabs 5 could be greater, or less, than those identified inthe preferred embodiment, depending on design needs. It is alsocontemplated that additional spacing patterns of the reinforcing tabs 5could be utilized to achieve a satisfactory result.

[0020] The end caps 4 also provide a means for securing a mounting pin 7to the heat exchanger unit. The mounting pins function to secure theheat exchanger to its operative location, such as within an automobileengine. The current practice is simply to weld mounting pins onto someportion of the heat exchanger unit—often the side support or the endcaps. In the preferred embodiment, small rectangular holes are drilledthrough the “radiator” cap member 4 a of the integrated side supportafter it has been stamped. In a separate process, mounting pins 7 arestamped that contain tabs at the cylindrical ends of the mounting pins.In the next step, the tabs of the mounting pins are placed through theholes that have been drilled in the cap member 4 a and then the tabs,now protruding through the cap member 4 a, are expanded through aprocess called stacking. The expansion of the mounting pin tabs securesthe mounting pins in place.

[0021] The present invention further contemplates the addition ofexpansion joints 6 on each end of the integrated side support 3.Preferably, the expansion joint 6 includes a pursed (or folded) portionof the flat area 3 a located adjacent the end cap 4. This configurationallows the pursed portion to lengthen and expand, thereby adding to thelength of the side support 3 itself. The addition of an expansion joint6 on each end of the side support 3 serves to allow for thermalexpansion during the operation of the heat exchanger. This is necessaryin that, as the core temperature of the heat exchanger rises duringoperation, core components 8 of the heat exchanger expand. If suchcomponents are rigidly contained within the core of the heat exchanger,components can become damaged and, in some instances, the side supportscan warp. The addition of the expansion joints 6 to the side support 3allows the side support 3 to flex which alleviates the problem ofdamaging the heat exchanger core components 8, as well as the warping ofthe side support 3 itself. An additional benefit is derived from theinclusion of expansion joints in that the expansion joints 6 allow theintegrated side support 3 to flex during the manufacturing process. Theprocess for manufacturing heat exchangers involves meshing what areoften inflexible components into a cohesive whole. The addition ofexpansion joints 6 in the preferred embodiment allows a degree offlexibility to the side support thereby making it easier to assemble thecomponents during the manufacturing process.

[0022] The manufacturing process of the integrated side support itselfconsists of creating a stamping die according to the neededspecifications. The utilization of a stamping die to create structuralcomponents is well known in the mechanical arts. For example, thestamping die can be utilized to form internal passageways in a tubularstructure or to create specific components to exacting detail for use inmachinery components, as is well-known in the art. Although thepreferred embodiment of the present invention has been described indetail herein, the invention is not limited thereto. It will beappreciated by those skilled in the art that various modifications canbe made without materially departing from the novel and advantageousteachings of the invention. For example, a traditional configuration ofjust a single heat exchanger, such as a radiator, would still benefitfrom the integrated side support. It is also possible that, at somepoint in the future, even more than two heat exchangers could becombined into an integrated unit. With slight modification in thestamping process, such a device could be accommodated by the presentinvention. Specifically, addition cap members could be added to the endcap to accommodate such a device.

[0023] It would be understood by those skilled in the art that the outerdimensions of the end cap 4, and specifically, the cap members 4 a, 4 b,would vary according to the required specification of the heat exchangercomponent it was to be joined with, and the indentation in the capmember would vary with the inner dimensions in a similar manner. Asstated, in the preferred embodiment, one cap member 4 a would fit to theouter diameter of a radiator header 1 while its indentation would fitwithin the inner diameter of the radiator header 1. The other cap member4 b would fit to the outer diameter of a condenser 2 while itsindentation would fit within the inner diameter of the condenser header2. While it is believed that those skilled in the art would understandhow to utilize a basic design configuration to achieve such a task, adetailed illustrative embodiment of the end cap 4 and its cap members 4a, 4 b is schematically illustrated in FIG. 3.

[0024] Of course, it should be understood that a wide range of changesand modifications can be made to the preferred embodiments describedabove. Thus, it is intended that the foregoing detailed description beregarded as illustrative rather than limiting, and that it be understoodthat it is the following claims, including all equivalents, which areintended to define the scope of this invention.

1. A heat exchanger comprising: at least one pair of integrated headersarranged parallel to each other, each integrated header comprising aradiator unit and a condenser unit, said radiator unit and saidcondenser units defining separate heat-exchange fluid flowpaths; aplurality of parallel heat transfer tubes connected perpendicularly tosaid integrated headers; a plurality of fins extending between adjacentheat transfer tubes; a fin unit including a plurality of fins mounted toan outside surface of an outermost heat transfer tube; and an integratedside support connected to said fin unit and said integrated headers,said side support extending along an outside surface of said outermostheat transfer tube.
 2. The heat exchanger of claim 1, wherein saidintegrated side support further comprises an elongated flattened portionhaving an end cap defined at each end, each of said end caps having aunitary structure extending between said radiator unit and saidcondenser unit.
 3. The heat exchanger of claim 1, wherein saidintegrated side support further comprises an elongated flattened portionhaving an end cap defined at each end, each of said end caps havingreinforcing tabs extending radially from annular portions of said endcaps.
 4. The heat exchanger of claim 1, wherein said integrated sidesupport further comprises expansion joints at both ends of saidintegrated side support.
 5. A heat exchanger comprising: at least onepair of integrated headers arranged parallel to each other, eachintegrated header comprising a radiator unit and a condenser unit, saidradiator unit and said condenser units defining separate heat-exchangefluid flowpaths; and a unitarily structured end cap positioned to covereach of said headers to block said flowpaths
 6. The heat exchanger ofclaim 5, wherein said unitarily structured end cap further comprises atleast two cap members integral with the said unitarily structured endcap, each cap member being capable of sealing a separate header unit. 7.The heat exchanger of claim 5, wherein said unitarily structured end capfurther comprises a molded indentation within each cap member thatcoincides with the inner diameter of a separate heat exchanger unit. 8.The heat exchanger of claim 5, wherein said unitarily structured end capfurther comprises reinforcing tabs extending radially from annularportions of said unitarily structured end caps.
 9. The heat exchanger ofclaim 5, wherein said unitarily structured end cap is integrally moldedwith a side support for a heat exchanger.
 10. Apparatus for supporting apair of integrated headers arranged in parallel relation to each othercomprising: a side support mounted adjacent both of said integratedheaders; end cap means integrated with said side support for sealingsaid integrated headers, and securing means extending from said end capmeans for securing said end cap means to said headers.
 11. The apparatusof claim 10 wherein said end cap means is integrally molded with saidside support.
 12. The apparatus of claim 10 wherein said end cap meanscomprises at least one cap member integrally molded within a unitarystructure.